Appendix E HAZOP Parameters, Deviations, and Possible Causes

The following are typical guideword parameter, deviations, and possible causes that are used
in HAZOP reviews. This listing is by no means exhaustive and each review should be
supplemented or tailored to meet the needs of a particular facility.

PARAMETER DEVIATION POSSIBLE CAUSES

FLOW
HIGH
0 Increased Pumping Capacity
0 Increased Suction Pressure
0 Reduced Delivery Head
0 Greater Fluid Density
8 Exchanger Tube Leaks
0 Restriction Orifice Plates Not Installed
0 Cross Connection of Systems
0 Control Faults
0 Control Valve Trim Changed
0 Running Multiple Pumps

LESS
0 Restriction
0 Wrong Routing
l Filter Blockage
0 Defective Pump(s)
0 Fouling of Vessel(s), Valves, Orifice Plates
a Density or Viscosity Changes
a Cavitation
0 Drain Leaking
0 Valve Not Fully Open

NONE
0 Wrong Routing
0 Blockage
0 Incorrect Slip Plate
0 One Way (Check) Valve In Backwards
0 Pipe or Vessel Rupture
0 Large Leak
0 Equipment Failure
0 Isolation in Error
0 Incorrect Pressure Differential
0 Gas Locking

REVERSE
0 Defective One Way (Check) Valve
0 Siphon Effect
0 Incorrect Pressure Differential

1Pl
I12 Application of HAZOP

0 Two Way Flow

0 Emergency Venting
0 Incorrect Operation
o In-Line Spare Equipment
l Pump Failure
l Pump Reversed

LEVEL
HIGH
Outlet Isolated or Blocked
Inflow Greater Than Outflow Control Failure
Faulty Level Measurement
Gravity Liquid Balancing
Flooding
Pressure Surges
Corrosion
Sludge

LOW
0 Inlet Flow Stops
0 Leak
0 Outflow Greater than Inflow
0 Control Failure
0 Faulty Level Measurement
0 Draining of Vessel
0 Flooding
0 Pressure Surges
0 Corrosion
0 Sludge

PRESSURE
HIGH
0 Surge Problems
0 Connection to High Pressure
0 Gas (Surge) Breakthrough
0 Inadequate Volume of Vents
0 Incorrect Vent Set Pressure for Vents
0 Relief Valves Isolated
0 Thermal Overpressure
0 Positive Displacement Pumps
0 Failed Open PCV
0 Boiling
0 Freezing
0 Chemical Breakdown
0 Scaling
0 Foaming
0 Condensation
0 Sedimentation
 Appendix E: HAZOP Parameters, Deviations, and Possible Causes 113

Gas Release
Priming
Exploding
Imploding
External Fire
Weather Conditions
Hammer
Changes in Viscosity/Density

Generation of Vacuum Conditions

Condensation
Gas Dissolving in Liquid
Restricted Pump/Compressor Line
Undetected Leakage
Vessel Drainage
Blockage of Blanket Gas Regulating Valve
Boiling
Cavitation
Freezing
Chemical Breakdown
Flashing
Sedimentation
Scaling
Foaming
Gas Release
Priming
Exploding
Imploding
Fire Conditions
‘Weather Conditions
Changes in Viscosity/Density

TEMPERATURE
HIGH
e Ambient Conditions
0 Fouled or Failed Exchanger Tubes
0 Fire Situation
0 Cooling Water Failure
0 Defective Control Valve
* Heater Control Failure
0 Internal Fires
0 Reaction Control Failures
0 Heating Medium Leak into Process
0 Faulty Instrumentation and Control

LOW
l Ambient Conditions
@ Reducing Pressure
If4 Application of HAZOP

0 Fouled or Failed Exchanger Tubes

0 Loss of Heating
0 Depressurization of Liquified Gas - Joule Thompson Effect
0 Faulty Instrumentation and Control

MATERIAL
WRONG
0 Incorrect or Off specification Feedstock
0 Incorrect Operation
0 Wrong Material Delivered

CONCENTRATION
WRONG
0 Leaking Isolation Valves
0 Leaking Exchanger Tubes
0 Phase Change
0 Incorrect Feedstock Specification
0 Process Control Upset
0 Reaction Byproducts
0 Ingress of: Water, Steam, Fuel, Lubricants, Corrosion Products from
High Pressure System
Gas Entrainment

CONTAMINANTS

Leaking Exchanger Tubes

Leaking Isolation Valves
Incorrect Operation of System
Interconnected Systems
Wrong Additives
Ingress of Air: Shutdown and Start-up Conditions,
Elevation Changes, Fluid Velocities
Ingress of: Water, Steam, Fuel, Lubricants, Corrosion
Products from High Pressure System
Gas Entrainment
Feed stream impurities (Mercury, H2S, CO, etc.)

VISCOSITY
MORE
0 Incorrect Material or Composition
0 Incorrect Temperature
0 High Solids Concentration
0 Settling of Slurries
 Appendix E: HAZOP Parameters, Deviations, and Possible Causes 115

LESS
0 Incorrect Material or Composition
0 Incorrect Temperature
0 Solvent Flushing

RELIEF SYSTEM
0 Relief Philosophy (process/fire)
0 Type of Relief Device and Reliability
0 Relief Valve Discharge Location
0 Pollution Implications
0 Two Phase Flow
0 Low Capacity (inlet and outlet)

CORROSION/
EROSION 0 Cathodic Protection Arrangements (internal and external)
0 Coating Applications
0 Corrosion Monitoring Methods and Frequencies
0 Materials Specification
0 Zinc Embrittlement
0 Stress Corrosion Cracking
0 Fluid Velocities
0 Sour Service (H,S, Mercury, etc.)
0 Riser Splash Zone

SERVICE
FAILURES
0 Instrument Air
0 Steam
0 Nitrogen
0 Cooling Water
0 Hydraulic Power
0 Electric Power
6 Water Supply
0 Telecommunications
0 PLC’sKomputers
0 HVAC
0 Fire Protection (Detection and Suppression)

ABNORMAL
OPERATION
0 Purging
0 Flushing
0 Startup
0 Normal Shutdown
e Emergency Shutdown
0 Emergency Operations
0 Inspection of Operating Machines
0 Guarding_ of Machinerv
II6 Application of HAZOP

MAINTENANCE
PROCEDURES
0 Isolation Philosophy
0 Drainage
0 Purging
0 Cleaning
0 Drying
0 Access
0 Rescue Plan
0 Training
0 Pressure Testing
0 Work Permit System
0 Condition Monitoring
0 Lift and Manual Handling

STATIC
0 Grounding Arrangements
0 Insulated Vessels
0 Low Conductance Fluids
a Splash Filling of Vessels
0 Insulated Strainers and Valve Components
0 Dust Generation
0 Powder Handling
0 Electrical Classification
0 Flame Arrestors
0 Hot Work
0 Hot Surfaces
0 Auto-ignition or pyrophoric materials

SPARE
EQUIPMENT
0 Installed/Not Installed
e Availability of Spares
0 Modified Specifications
0 Storage of Spares
0 Catalog of Spares

SAMPLING
PROCEDURES
0 Sampling Procedure
0 Time for Analysis Results
l Calibration of Automatic Samplers
o Reliability/Accuracy of Representative Sample
l Diagnosis of Results
 Appendix E: HAZOP Parameters, Deviations, and Possible Causes 117

TIME
0 Too Long
0 Too Short
0 Wrong Time

ACTION
Overkill
Underestimated
None
Reverse
Incomplete
Knock-on
Wrong Action

INFORMATION
0 Confusing
0 Inadequate
0 Missing
0 Misinterpreted
0 Partial
0 Stress
0 Wrong Information

SEQUENCE
0 Operation too early
0 Operation too late
0 Operation left out
0 Operation performed backwards
0 Operation not completed
0 Supplemental action taken
0 Wrong action in operation

SAFETY SYSTEMS
0 Fire and Gas Detection and Alarms
0 Emergency Shutdown Arrangements (ESD)
0 Fire Fighting Response
0 Emergency Training
0 TLVs of Process Materials and Method of Detection
* First Aid/Medical Resources
0 Vapor and Effluent Disposal
0 Testing of Safety Equipment
0 Compliance with Local and National Regulations

GLOBAL
Layout and Arrangement
Weather (Temperature, Humidity, Flooding, Winds,
Sandstorm, Blizzards, etc.)
Geological or Seismic
Human Factors (Labelling, Identification, Access, Instructions,
118 Application of HAZOP

Training, Qualifications, Alarms, etc.)

0 Fire and Explosion
0 Adjacent Facility Exposures